Professional Documents
Culture Documents
Steve Goidich
Presented at:
PowerGen International
Orlando, Florida
November 2000
INTEGRATION OF THE BENSON VERTICAL OTU TECHNOLOGY
AND THE COMPACT CFB BOILER
Stephen J. Goidich, Foster Wheeler Energy International
ABSTRACT
Circulating fluidized bed (CFB) boilers offer increased operational flexibility because of the
ability to fire a range of fuels in the same unit. Fuels fired can include waste and low grade fuels
which cannot be fired in conventional units. In-furnace capture of sulfur dioxide by limestone
addition, and low NOx emissions resulting from low operating furnace temperature (850-900°C)
and staged combustion make CFB units an environmentally friendly means to generate steam.
Once-through utility (OTU) boilers can be operated at supercritical pressures [>220 bar (3200
psia)] since they do not rely on the density difference between steam and water to provide
circulation through the furnace enclosure tubes; fluid circulation is maintained by the boiler
feedpump. Operation at supercritical pressures provides a significant increase in steam cycle
efficiency which results in reduced fuel consumption. The coupling of supercritical OTU and
CFB technologies offers a very attractive way to produce power in the 150 to 600 MWe size
range.
Described in this paper is how the Siemens BENSON Vertical OTU technology is integrated
into the Compact CFB boiler configuration offered by Foster Wheeler. Critical to the design of
a once-through boiler is the ability to accommodate heat absorption variations without
overheating the furnace enclosure tubes. Historically this has been done by designing for high
fluid mass flow rates which results in high pressure losses and therefore increased auxiliary
power consumption. The BENSON Vertical technology provides a means to design for low
mass flow rates with a simple, single vertical pass configuration which can safely accommodate
full variable steam pressure operation. The Compact CFB boiler, with its minimal use of
refractory which results from having cooled separator, sealing device, and INTREX heat
exchanger, allows for rapid load changes to meet the requirements for full variable pressure
operation. The unique features of the BENSON Vertical OTU and Compact CFB boiler are
discussed as well as start-up system requirements. A design for a 350 MWe Compact OTU CFB
boiler is described.
INTRODUCTION
Large scale conventional utility boilers which fire high grade fuels such as pulverized coal (PC),
oil, and/or natural gas can be and have been configured as either “drum” or “once-through”
types. However, circulating fluidized bed units, with a few exceptions, have primarily been
configured as “drum” type units.
In drum type units (see Figure 1) the steam flow rate is controlled by the fuel firing rate.
Superheat steam temperature is determined by the proper sizing of the superheater heat transfer
surface and controlled by spray water attemperation. In a once-through type boiler, the steam
flow rate is established by the feedwater pump, and the superheat steam temperature is controlled
by the fuel firing rate. Since the once through boiler does not rely on the density difference
between steam and water to provide proper circulation and cooling of the furnace enclosure
tubes, it can be operated at
supercritical [>220 bar (3200 PRINCIPLE NATURAL CIRCULATION (DRUM) ONCE-THRU
Historically, once through boilers have been designed for high steam/water mass flow rates to
minimize peak tube metal temperatures and limit the differential temperature between adjacent
enclosure wall tubes. To provide high mass flow rates, the evaporative furnace walls have been
designed in a multiple pass arrangement which also limits the heat absorption per pass and
therefore potential temperature unbalances within a pass. However, this type of an arrangement
requires operation at supercritical pressure over the load range to avoid two-phase flow related
problems that can occur when trying to distribute steam/water mixtures between passes. As a
result, there is a throttling pressure loss during low load operation.
Another method for achieving high mass flow rates is to incline the furnace enclosure tubes in a
single pass, spiral arrangement. This allows fewer tubes to form the required furnace enclosure.
Also, since all tubes wrap around through all enclosure walls, heat absorption and therefore tube
metal temperature unbalances are minimized. Since a single pass is used, the unit can operate at
subcritical pressure during part load or cycling operation which improves part load cycle
efficiency and makes it easier to match steam and turbine blade metal temperature for improved
steam turbine life. However, the spiral tube arrangement is not acceptable for CFB boiler
application because the inclined enclosure tubes would be subject to erosion. In CFB boilers,
fuel and sorbent ash are entrained in the flue gas which passes up through the furnace. A
significant amount of the entrained solids reflux (fall down) along the furnace walls. Any
protrusion which changes the direction of the falling solids can cause an erosive condition.
The current state-of-the-art technology for once-through boiler design is the BENSON Vertical
technology developed by Siemens through extensive research and development, and field-
testing. This technology offers significant functional and economic advantages for OTU power
generation. In order to incorporate these advantageous features into Foster Wheeler
conventional and CFB boilers, FW became a licensee of the BENSON Vertical technology.
Features of the BENSON Vertical technology and how it has been integrated into the FW
Compact CFB boiler system are described below.
“Natural Circulation” Characteristic. The most important requirement for the configuration
of the evaporative circuit in a furnace is to minimize peak tube metal temperatures and limit the
differential temperature between adjacent enclosure wall tubes. As noted above, this has
traditionally been done by ensuring sufficiently high steam/water mass flow rates through the
tubes over the once through operating load range.
In the BENSON Vertical design, the furnace vertical enclosure tubes are selected so that a
relatively low mass flow rate (about 1000 kg/m2-s) results at full load. This mode of operation is
termed to have a “natural circulation” characteristic because an excessively heated tube will
have an increase in flow because the
hydrostatic pressure loss is much greater
than the friction loss (see Figure 3). The
reduction in hydrostatic head is greater
than the increase in friction loss so that
the excessively heated tube receives
more flow. The steam temperature rise
in this circuit is limited because of the
corresponding increase in fluid flow
through the tube.
As a result of the low and uniform operating temperature with the CFB furnace, the heat flux to
the enclosure walls of the furnace are considerably lower than in a pulverized coal furnace as
shown in Figure 6. The lower 4-8 m of the CFB furnace is protected by refractory to prevent
corrosion due to the substoichiometric atmosphere, and to prevent erosion due the dense bed of
solids. As a result the heat
absorption in this area is minimal.
The highest heat fluxes occur just
above the refractory protected
area. In this transition region,
there is a significant amount of
refluxing (falling back) of the
particles which are too coarse to
be completely entrained by the
rising flue gas. As a result, the
solids concentration and therefore
the heat transfer to the furnace
walls is highest in this region.
However, the peak to average heat
flux is considerably lower than in
a pulverized coal furnace.
Figure 6. PC vs CFB Heat Flux
Because of the low and uniform
heat fluxes in a CFB furnace,
mass flow rates lower than that required for a conventional furnace can be used without concern
for departure from nucleate boiling (DNB) or dryout (see Figure 7). A full load mass flow rate
in the 500 to 700 kg/m2-s range can be used to achieve the “natural circulation” characteristic.
Figure 8 shows that for part load operation
with subcritical pressure and with smooth
tubes and low mass flow rates (55% of that
used for PC design), there is not a
significant rise in tube temperature at the
dryout point because of the low heat fluxes
that are characteristic of a CFB furnace.
Compact Separator. A main distinguishing feature of a CFB boiler is the separating device at
the furnace outlet that collects
unburned fuel and bed material
entrained in the flue gas and returns
it back to the lower furnace. The
separator can take many forms, but
the most common in the industry
has been the cyclone.
INTREX Heat Exchanger. Another innovation that enhances the Compact CFB boiler
design is the Integrated Recycle Heat Exchanger (INTREX) which provides the additional
solids cooling needed for larger boilers where the furnace walls are no longer sufficient (Ref. 3).
The INTREX is a bubbling bed heat
exchanger consisting of one or more tube
bundles that further cools the solids collect
by the separator before they are returned to
the furnace (see Figure 13). In addition to
cooling the externally circulated solids,
openings in the furnace rear wall provides
access for additional solids to internally
circulate through the INTREX tube bundles
ensuring sufficient hot solids to the INTREX
at all loads. Excess solids spill back into the
furnace through openings in the furnace rear
wall.
The enclosure is formed by water-cooled tubing that is integrated with the furnace circuitry.
This integrated configuration allows the INTREX to grow downward with the furnace enclosure
so that large maintenance prone expansion joints are not required.
Figure 14 illustrates a 350 MWe Compact CFB BENSON Vertical boiler. This particular design
utilizes two (2) double vortex COMPACT solids separators which are positioned on one side of
the furnace. Solids entrained in the flue gas are collected by the separators and are cooled by
four (4) INTREX heat exchangers which contain superheat heat transfer surface. The duty of the
INTREX is selected to maintain the desired furnace operating temperature for optimum emission
control and fuel burnup as well as to efficiently provide final superheat duty.
START-UP SYSTEMS
To start-up a once-through boiler, the steam/water pressure parts and the steam turbine must be
warmed and brought on-line in a safe and controlled manner that will not cause damage to any
component. To do this, a load is defined below which the unit is controlled in a manner similar
to a drum type unit (firing for pressure/steam flow). In-line separators are provided to collect
steam for warming the superheater pressure parts and the steam turbine. Water collected is
returned back to the furnace to maintain a minimum mass flow rate for proper tube cooling.
Above this defined minimum load, the unit is operated and controlled as a once-through boiler
(firing for steam temperature).
For the Compact CFB BENSON Vertical boiler, the minimum BENSON load is usually
established between 35 to 40% load. This requires establishing a minimum mass flow rate of 35
to 40% of the full load flow rate through the furnace walls. To do this, a recirculation pump is
used to superimpose a recirculating flow onto the flow provided by the boiler feedpump. Figure
15 illustrates the recirculation pump system.
Steam collected in the separators flows through the superheater circuitry and is dumped to the
condenser via the high pressure bypass station, the reheater, and the low pressure bypass station
during the initial start-up phase, and later, via the high pressure turbine, the reheater, and the
intermediate/low pressure turbine.
The first formation of steam in the furnace tubes causes a small amount of water to be discharged
from the water collection vessel to the atmospheric flash tank when the maximum level in the
tank is reached. The water from the atmospheric flash tank flows to the condensate tank and
from there is either pumped back to the feed tank via the deaerator or discharged to atmosphere
depending on the water quality.
A minimum recirculation pump flow line is provided to protect the pump. The valve in this line
is closed when the minimum flow rate is achieved.
A subcooling line is provided to allow low temperature feedwater to be admitted to the saturated
water in the water collecting vessel during recirculation. This subcooling of the water prevents
the formation of steam bubbles in the recirculating pump suction line even when the rate of
pressure reduction is high.
DYNAMIC BEHAVIOR
Extensive modeling work has been conducted by FW to understand the dynamic response
characteristics of the Compact CFB
BENSON Vertical boiler. The major
objective of the work was to develop a
control system to coordinate the heat
flow to the boiler water/steam according
to the energy output requirements placed
on the unit.
CONCLUSIONS
The BENSON Vertical once-through boiler technology, with its “natural circulation”
evaporation circuit characteristic, is ideally suited for CFB boiler application. The range of fuels
firing capability, low pollutant emissions, and high efficiency provide for cost effective power
production. Features such as the Compact separator and INTREX heat exchanger further add to
operational flexibility, low maintenance costs, and increased reliability.
REFERENCES
1. Siemens BENSON Boiler Brochure, “Research & Development at the BENSON Test
Rig” by Siemens AG , Power Generation KWU.
3. S.J. Goidich, T. Hyppanen, K. Kauppinen, “CFB Boiler Design and Operation Using the
INTREX Heat Exchanger, 6th International Conference on Circulating Fluidized Beds,
Würzburg, Germany, August 22-27, 1999.